Apparatus and method for producing a silk screen matrix

ABSTRACT

A method and apparatus for producing a silk screen matrix wherein a master, having contrasting characters scribed thereon that are to be reproduced is scanned by an electronic scanning device. The scanning device converts light or dark images on the master to electronic impulses. These impulses are transmitted to a punching apparatus, where they are used to activate a punch, which may be pneumatically or mechanically powered. The punch either includes a single die that travels across a matrix of paper, or other suitable material, punching holes corresponding to the light or dark areas on the master as it travels, or it includes a plurality of individually operated dies arranged in series across the mat and arranged such that operation of the dies in response to sensing of light or dark by the scanning device will punch holes through the mat. Either disclosed apparatus will thereby produce a punched matrix suitable for use in a silk screen printing operation.

United States Patent [1 1 Christensen 1 1 APPARATUS AND METHOD FORPRODUCING A SILK SCREEN MATRlX [75] Inventor: Leland C. Christensen,Mountain Green, Utah [22] Filed: Jan. 25, 1971 [21] Appl. No.: 109,212

[52] U.S. C1 234/2, 101/1284, 234/82 [51] Int. Cl. B4lc 1/14 [58] Fieldof Search 234/1, 2, 59, 89,

' w/Lg/ Primary Examiner-Frank T. Yost Attorney-B. Deon Criddlc [57]ABSTRACT A method and apparatus for producing a silk screen matrixwherein a master, having contrasting characters scribed thereon that areto be reproduced is scanned by an electronic scanning device. Thescanning device converts light or dark images on the master toelectronic impulses. These impulses are transmitted to a punchingapparatus, where they are used to activate a punch, which may bepneumatically or mechanically powered. The punch either includes asingle die that travels across a matrix of paper, or other suitablematerial, punching holes corresponding to the light or dark areas on themaster as it travels, or it includes a plurality of individuallyoperated dies arranged in series across the mat and arranged such thatoperation of'the dies in response to sensing of light or dark by thescanning device will punch holes through the mat. Either disclosedapparatus will thereby produce a punched matrix suitable for use in asilk screen printing operation.

1 Claim, 7 Drawing Figures PAIENTEU 3 SHEET 10F 3 FIG FIG 2 INVENTOR.LELAND C. CIHRISTENSEN ATTORNEY PMENTEW 3.762.636

SHEET 2 BF 3 III,IIIIIIlII'IIIIIIIIIIIIIIIIIIIIIIIIIII'IIIII lllllINVENTOR. LELAND C. CHRISTENSEN BY. Ed," 4%

ATTORNEY PATENTEDUCT 2197s SHEET 3 0F 3 FIG 6 FIG 7 lfllll mum IB'IIIIIIIIIlII/IIIII/IIIIIIIII IIIII .1- llll 1/11/11,!!!

a.\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\t6 fiV-l FA IVA VA VA VA VA I% LELAND C. CHRISTENSEN ATTORNEY APPARATUS ANDMETHOD FOR PRODUCING A SILK SCREEN MATRIX BRIEF DESCRIPTION OF THEINVENTION 1. Field of the Invention This invention relates to theproduction of a matrix suitable for use in a silk screen printingprocess.

2. Prior Art The introduction of the printing press has been creditedfor launching the world into the industrial revolution. Since itsinception printing has been practiced utilizing a multitude of devicesand techniques, among them silk screen printing. Silk screen printingwas originally developed by the Chinese at least 1,000 years ago, andhas been utilized and perfected by them to a high degree for theproduction of art. Numerous refinements have been added to this printingtechnique since its acceptance in this country. Silk screen printingencompasses many processes and procedures such as, for example, a photosilk screen process which is slow and expensive, but which is capable ofan extremely high quality reproduction even of full color photography. Amethod involving the cutting out of areas on a soluble plastic filmproduced for this purpose, and then adhering the film to the silk isalso extensively used. The soluble film bonds itself to the silk,blocking out portions of the silk permanently or may be removed with theproper solvent for the type of film being used. A process devised by theorientals involves applying paint or other suitable material to thesilk, thereby blocking out that portion of the silk. Another processutilizes a stencil or matrix having a design cut therein, which stencilor matrix is placed in a frame between a silk screen and the material tobe printed. Silk screen paint or dye is applied to the screen and isdistributed evenly thereon. The silk allows passage through to thestencil or matrix which passes said dye or paint to the material to beprinted through holes cut therein. The result is a design that is bothdistinctive and attractive. The present invention constitutes animprovement in the known techniques involving silk screen printing.

Prior to the present invention the methods used in preparing the matrixor stencil have been generally difficult to employ and inefficient, withthe quality of the finished matrix varying with the skill of theindividual workers practicing the method. As the quality of the matrixcontrols or dictates the quality of the finished product, the value ofthe finished work has varied. The present invention eliminates the handcutting of the design into the matrix. Rather, the process of matrixpreparation is completely automated and there is produced in far lesstime than can be achieved by hand operations, a finished matrix ofuniform quality for use in silk screen printing. The process andapparatus of the invention are especially useful in the production ofposters and other large articles of printed materials. Artistry of aunique and original character can be obtained with the method andapparatus of the present invention.

SUMMARY OF THE INVENTION It is a principal object of the presentinvention to provide a method and an automated apparatus forelectronically and mechanically producing a silk screen matrix directlyfrom a master pattern.

Principal features of the present invention include the use of aconventional Zerox Photocopier ll produced and sold by the ZeroxCorporation, or similar electronic scanning device, to transform eitherthe light or the dark portions of an original or master design toelectrical impulses. These impulses are transmitted electronically to ahole punching means which acts across a width of matrix of paper,fabric, or other suitable sheet material as it is travelling through theapparatus. The punching means is automatically operated in accordancewith the electrical impulses to punch holes in the matrix such that thepattern of punched holes then reproduces either the light or the darkareas of the master.

A variety of hole punching means have been found suitable for use. Inthe preferred embodiments, these are all solenoid activated with eachoperating to punch holes that correspond to either the light or darkareas of the master. In one embodiment, there is only one solenoidinvolved in the punching operation. This solenoid operates a hammer tostrike the head of a selected punch that is one of a plurality ofpunches arranged in a punch bar extending across the width of matrixmaterial as it travels beneath the punch means. The solenoid travels ona threaded track positioned above the punch bar striking the heads ofthe punches in accordance with the master design. In this embodiment,the speed of hole punching is governed by how fast the solenoid operatedhammer can reciprocate across the paper but there is no physicalrestriction on the proximity of adjacent punches.

In another embodiment, the hole punching means comprises a number ofaligned solenoid operated hammers which are fixed in position to extendacross the width of the matrix material. Each hammer is positioned tooperate a punch on a punch bar which also extends across the width ofthe matrix material. In this embodiment, as the matrix material is drawnthrough the assembly the stationary solenoid operated punches areelectrically operated to punch holes corresponding to the light or darkareas of the master design. Punched matrixes can be produced much morerapidly in this embodiment as no solenoid movement is required, but itis more expensive due to the number of individual solenoid hammers thatare needed and the physical arrangement of heads may limit the proximityof adjacent punches.

Still another embodiment of the hole punching means utilizes an airpunch rather than the electromechanical punch previously described asbeing used in the hole punching means. This punch utilizes a highpressure jet of compressed air directed against a sharp edged backingmember to punch a clean hole in the matrix material. The air jet can beprogrammed toreciprocate across the width of the material on a track, orit can consist of a number of jets arranged above the material andoperated by the electronic scanning device to release jets of compressedair so as to punch holes corresponding to either a light or a darkportion of the master. This embodiment can effectively use solenoidoperators to open and close valves controlling the entrance ofcompressed air into the air jet but other quick acting controls can beused.

It will be apparent that the apparatus can utilize punches of varyingsize to correspond to different sized light dark images sensed and thatthe size punch used can be selected from a plurality of sizes availablefor punching use. Thus, if the sensed signal indicates that one sizepunch should be used a corresponding punch will be operated. If the nextsignal indicates that a different sized punch should be used, adifferent sized punch will next be operated. While not specificallyshown, a rotating punch head having a plurality of punches of differentsize can be provided or the punches can be telescopically arranged suchthat a punch of selected size will be operated in response to a signalfrom a sensing device. Thus the same matrix may have punch holestherethrough of several different sizes corresponding to light-darkimages of different sizes on the master.

Further objects and features of the invention will become apparent fromthe following detailed description, taken together with the accompanyingdrawings.

THE DRAWINGS FIG. 1 is a perspective view of a hole punching apparatusconsisting of one solenoid operated hammer which traverses the width ofa sheet of matrix paper acting upon punches in a punch block;

FIG. 2, an enlarged section taken on the line 22 of FIG. 1, and showingthe solenoid operated hammer acting upon a punch in the punch bar;

FIG. 3, a perspective view of a hole punching apparatus consisting of anumber of stationary solenoids and hammers positioned so as to act uponpunches in the punch bar; and

FIG. 4, an enlarged section taken on the line 4-4 of FIG. 3, and showingthe row of fixed solenoid operated hammers acting upon punches in thepunch bar;

FIG. 5, an enlarged view of a solenoid operated air punch positioned soas to operate to punch a hole in matrix paper;

FIG. 6, a perspective view of a hole punching apparatus consisting of anumber of stationary solenoid operated air punches positioned so as tooperate to punch holes in matrix paper; and

FIG. 7, an enlarged fragmentary section taken on the line 77 of FIG. 6,and showing the row of fixed solenoid operated air punches positioned tobe operable to punch holes in a matrix material.

DETAILED DESCRIPTION Referring now to the drawings:

FIG. 1 illustrates one preferred embodiment ofa matrix punchingapparatus of the present invention. The hole punching apparatus showngenerally at 10, includes a frame 11 which supports a roll of matrixpaper 12. The roll of matrix paper is mounted on an axle 13 that isjoumaled at its ends in notches 14a and 14b inside rolls of frame 11 sothat the roll turns freely, thereby allowing the matrix paper 12 to beunrolled.

The matrix paper 12 travels over rollers 15a and 15b, that are alsojoumaled between the side rails of frame 1 I, then travels through theproximity of the assemblies hold punching means shown generally at 10.As shown in FIGS. 1 and 2, the hole punching means consists of a singlesolenoid 17 which is electrically connected by wires 17a and 17b to aconventional electronic scanning device, shown schematically at 16. Thesolenoid 17, when electrically activated by signals from the scanningdevice, causes a hammer 18 (FIG. 2) to strike a punch 19, which is oneof a number of punches in a punch bar 20 that is supported by frame 11in such a manner that it extends over the width of matrix paper 12. Aspring 21 normally biases punch 19 to a raised, retracted position, outof contact with the matrix paper 12 passing therebeneath. When a punch19 is actuated to punch a hole in the matrix paper 12 it travels throughthe paper and into a hole 22, formed in a die or punch block 23 that isalso supported by the frame 11, and beneath punch bar 20.

The solenoid l7 and hammer 18 are attached to a bracket 24 by screws 24aand 24b. The bracket 24 has parallel sleeves 25 and 26 at opposite sidesthereof, and sleeve 26 is slidably telescoped over a rod 28 that isconnected at both ends to the side rails of the frame. In operation thesolenoid hammer assembly is guided by rod 28 to reciprocate above thepunch bar 20. The solenoid hammer assembly is reciprocated by therotation of a threaded rod 29 which is operated by a reversible motor 30and that is threaded to cooperate with threads on the inside of sleeve25.

Motor 30 is electrically connected to the electrical scanning device 16which is also electrically connected to solenoid 17. Motor 30 turnsthreaded rod 29 to position the solenoid hammer assembly in conjunctionwith the sensed position of the elctrical scanner. When the scannersenses an area programmed to cause a hole to be punched in matrix paper12, a signal is transmitted to solenoid 17 which causes hammer 18 tostrike the punch 19 then beneath it, forcing the punch through matrixpaper 12. Thereafter, the punch 19 is retracted by its associated spring21.

Another motor 32 drives a roller 34 which, along with idler roller 33,is journaled in the side rails of frame 1 1, motor 32 is alsoelectrically connected to the electronic scanning device 16. On signalfrom the scanning device, motor 32 is operated, thereby turning driveroller 34 to pull matrix paper 12 through the hole punching assembly andbetween the drive and idler rollers 34 and 33. The direction of travelof bracket 24 is determined by the direction of rotation of motor 30,and this is determined by the sensing device 16. In practice the bracketis moved in one direction across the matrix, the matrix is stepped byoperation of motor 32 and the bracket and solenoid and hammer carriedthereby are moved in a reverse direction across the matrix.

In the embodiment shown in FIG. 3, an electronic scanning device 38again transmits signals to means for moving a matrix paper 12, such thatit can be acted upon by a hole punching assembly 39, and to the holepunching assembly. In this embodiment, as is shown best in FIG. 4,however, a plurality of solenoid operated hammers 40 (corresponding tohammer l8, previously described) are permanently positioned above apunch bar 41 and a punch block 42. The number of hammers corresponds tothe number of individual punches 43 and to the holes 44 in the bar 41.The solenoid operated hammers 40 are permanently installed above and actupon the punch bar 41 and the punch block 42 so that no motor, such asthe motor 30 of the previously described embodiment is needed and nothreaded rod such as the rod 29 is required. A motor 49, correspondingto motor 32 previously described, is connected electrically to theelectronic scanning device and turns a roller 50, thereby pulling matrixpaper 12 through the punching assembly. Since no solenoid hammer travelis involved, in this embodiment, hammer actuation is more rapid than ispossible in the first embodiment which utilizes a travelling solenoidhammer. However, the physical arrangement may dictate the number ofhammers, punch bars, and punch holes that can be used.

In still another embodiment of the invention, the hole punching assemblycomprises a solenoid operated high pressure air punch. The punch of thisembodiment is mounted on guide rods as in the other embodiments and canbe installed so as to traverse the width of the matrix paper 12, as inthe first described embodiment or can be one of a number of stationaryair punches op erated as in the second described embodiment. Thedistinction between the mechanical punch of the other describedembodiments and the air punch of this embodiment is that the solenoid ofthe hole punching assembly, which is operated in response to a signalfrom an electronic scanning device, is connected to a valve. The valve,when opened, allows high pressure air flow from a compressed air source,not shown, through a header pipe and into and through a dischargeorifice of the air punch, to act upon the matrix paper 12. This causes ashearing effect of the paper as it contacts the edges of an opposed holein the punch block and leaves a hole in the paper of the same size andshape as in the punch block.

As shown in FIGS. 6 and 7, a plurality of discharge orifices 56 can beconnected to a single header 55 such that they extend completely acrossthe matrix paper 12 and that each orifice can be controlled by aseparate valve 54. The valves 54 are operated in response to signalsfrom the electronic scanning device such as is shown at 38 in FIG. 2. Inthis embodiment, as with the embodiment of FIG. 3, a fast response canbe obtained, since the hole punching assembly does not have to move,but, also like the embodimentv of FIG. 3, the physical arrangement ofstructure may dictate the distance between punches.

Alternatively as in the embodiment of FIGS. ii and 2, a single punch canbe used for the hole punching assembly 53. In this case, as shown inFIG. 5, a single discharge orifice 56 is arranged to reciprocatetransversely to the direction of travel of matrix paper 12. The orifice56 is exteriorly threaded and is fixed by nuts 57 and 58 to a bracket59, (corresponding to the bracket 24 of FIGS. 1 and 2) that is guided byrods 60 and 6t passed through parallel sleeves 62 and 63 of the bracketand that is driven by engagement of interior threads of sleeve 62meshing with threads on rod 60. When compressed air is introducedthrough a valve 54, orifice 56 directs it through an oppositelypositioned hole 64 in a punch block 65, thereby making a punched hole inthe matrix paper 12 which passes between orifice 56 and hole 64. Rod 60is driven in the same manner as is rod 29, previously described by amotor, not shown. A flexible conduit allows free travel of the holepunching assembly, while insuring air flow to the orifice. The valvesused may be solenoid operated, in response to signals from theelectrical scanning device, and can be of any conventional quick openingtype.

While particular hole punching apparatus have been herein disclosed, andthese apparatus are preferred for many purposes, other methods ofpunching holes in a paper to create a matrix or stencil conforming to amaster design in response to an electrical sensing of said master designcan be used to practice the method of the invention, which method Iregard as my invention. For example, a movable punch and acorrespondingly movable punch block (not shown) may be used to provide asystem with wide versatility since it does not require punching atpre-set locations.

Although preferred forms of apparatus of my invention have been hereindisclosed, it is to be understood that the present disclosure is by wayof example and that variations are possible without departing from thesubject matter coming within the scope of the following claims, whichsubject matter I regard as my invention.

I claim:

1. A method of producing a silk screen matrix from an imaged mastercomprising sensing the images of a master to be copied;

generating electrical signals corresponding to the sensed images;transmitting said electrical signals on a row-by-row basis to punchmeans; and

feeding a matrix suitable for use in silk screen printing past saidpunch means such that said punch means is operated by said electricalsignals to punch holes through the said matrix on a row-byrow basis,with each hole corresponding to a portion of a sensed image in acorresponding row on

1. A method of producing a silk screen matrix from an imaged mastercomprising sensing the images of a master to be copied; generatingelectrical signals corresponding to the sensed images; transmitting saidelectrical signals on a row-by-row basis to punch means; and feeding amatrix suitable for use in silk screen printing past said punch meanssuch that said punch means is operated by said electrical signals topunch holes through the said matrix on a row-by-row basis, with eachhole corresponding to a portion of a sensed image in a corresponding rowon the master.